Applicator for applying and distributing substances to target surfaces

ABSTRACT

The present invention provides an applicator for applying and distributing a substance onto a target surface. The applicator comprises a substantially planar sheet of compressible, conformable material having opposed first and second surfaces and an interior region between said first and second surfaces. The sheet of material has a thickness between the first and second surfaces which decreases when the sheet of material is subjected to an externally-applied force in a direction substantially normal to the first surface. The applicator further includes at least one discrete reservoir extending inwardly of the first surface into the interior of the sheet of material which is at least partially filled with a substance and at least one discrete aperture formed in the first surface which is in fluid communication with the reservoir. Compression of the sheet of material via an externally-applied force substantially normal to said first surface expresses product from the aperture and translational motion of the first surface relative to a target surface applies and distributes said product onto the target surface. In a preferred embodiment, a plurality of apertures are associated with corresponding reservoirs forming a delivery zone near one end of a hand-held applicator, and the sheet material is preferably resilient both in compression and in bending to conform to irregular target surfaces. A wide variety of substances are contemplated, including particularly antiperspirant/deodorant products. Other embodiments include a single reservoir feeding a plurality of apertures.

FIELD OF THE INVENTION

[0001] The present invention relates to applicators for use in manuallyapplying coatings of a substance onto a desired target surface. Moreparticularly, the present invention relates to such applicators whichprovide both dispensing and distribution functionality and thereforeenhanced product performance.

BACKGROUND OF THE INVENTION

[0002] There are many types of topical products that are commerciallyavailable and/or commonly applied to a desired (target) surface in theform of a thin film or coating to protect, treat, modify, etc. thetarget surface. Such products include those in the skin care, cosmetics,pharmaceutical, and other personal care arenas. One common example ofsuch a product is the antiperspirant/deodorant type of product, many ofwhich are formulated as sprays, roll-on liquids, gels, creams, or solidsticks, and comprise an astringent material, e.g. zirconium or aluminumsalts, incorporated into a suitable topical carrier. These products aredesigned to provide effective perspiration and odor control while alsobeing cosmetically acceptable during and after application onto theaxillary area or other areas of the skin.

[0003] Examples of suitable perforated caps or other shear forcedelivery means for use with such packaged compositions include thoseknown in the art for application of creams, or those delivery means thatare otherwise effective for delivering the composition of the presentinvention to the skin, with the resulting rheology of the extrudedproduct preferably falling within the ranges described hereinabove forextruded compositions. Some examples of such perforated caps or othershear force delivery means, and some dispensing packages for use withcompositions herein, are described in U.S. Pat. No. 5,000,356, issued toJohnson et al. on Mar. 19, 1991, which description is incorporatedherein by reference.

[0004] While such delivery means have proven successful in applying suchsubstances, in many instances a comparatively complex supply mechanismis required in order to dispense the product for application by shearforce delivery means. This in turn typically requires a comparativelylarge canister to house not only the desired quantity of product butalso the product retention and supply mechanism as well. Economicfactors also typically require even travel size canisters for bothelevator-type and push-up-stick packages to have considerable weight andoccupy considerable volume, thus limiting the ability of the consumer toreadily transport such devices. Moreover, such constructions for allpractical considerations preclude the carrying of such devices on one'sperson such as in a pocket or modest-sized purse for replenishment ofone's antiperspirant or deodorant during the course of an extended stayaway from home.

[0005] Accordingly, it would be desirable to provide a discrete,convenient hand-held applicator for applying substances to targetsurfaces.

[0006] It would also be desirable to provide such an applicator whichprovides for a substantially uniform coating of such substances to yieldenhanced product performance.

[0007] It would also be desirable to provide such an applicator which iseasy to use and may be economically produced.

SUMMARY OF THE INVENTION

[0008] The present invention provides an applicator for applying anddistributing a substance onto a target surface. The applicator comprisesa substantially planar sheet of compressible, conformable materialhaving opposed first and second surfaces and an interior region betweensaid first and second surfaces. The sheet of material has a thicknessbetween the first and second surfaces which decreases when the sheet ofmaterial is subjected to an externally-applied force in a directionsubstantially normal to the first surface. The applicator furtherincludes at least one discrete reservoir extending inwardly of the firstsurface into the interior of the sheet of material which is at leastpartially filled with a substance and at least one discrete apertureformed in the first surface which is in fluid communication with thereservoir. Compression of the sheet of material via anexternally-applied force substantially normal to said first surfaceexpresses product from the aperture and translational motion of thefirst surface relative to a target surface applies and distributes saidproduct onto the target surface. In a preferred embodiment, a pluralityof apertures are associated with corresponding reservoirs forming adelivery zone near one end of a hand-held applicator, and the sheetmaterial is preferably resilient both in compression and in bending toconform to irregular target surfaces. A wide variety of substances arecontemplated, including particularly antiperspirant/deodorant products.Other embodiments include a single reservoir feeding multiple apertures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] While the specification concludes with claims which particularlypoint out and distinctly claim the present invention, it is believedthat the present invention will be better understood from the followingdescription of preferred embodiments, taken in conjunction with theaccompanying drawings, in which like reference numerals identify likeelements and wherein:

[0010]FIG. 1 is a plan view of a preferred embodiment of an applicatorin accordance with the present invention;

[0011]FIG. 2 is an elevational sectional view of the applicator of FIG.1 taken along section line 2-2;

[0012]FIG. 3 is a schematical illustration of the applicator of FIGS. 1and 2 being utilized to manually apply a coating of a substance to atarget surface;

[0013]FIG. 4 is a plan view similar to FIG. 1 of another embodiment ofan applicator; and

[0014]FIG. 5 is an elevational sectional view similar to FIG. 2 of theapplicator of FIG. 4 taken along section line 5-5.

DETAILED DESCRIPTION OF THE INVENTION

[0015] 1. Applicator Construction.

[0016]FIG. 1 depicts a preferred embodiment of an applicator 10 inaccordance with the present invention. Applicator 10 comprises asubstantially planar sheet of material 20 having a first side 21 and asecond side 22, with the first and second sides defining an interiorregion 23 of the material 20. The first side 21 includes at least oneaperture 30, and preferably a plurality of apertures 30 forming adelivery zone 31. The delivery zone 31 encompasses not only theapertures 30 but also the interstitial spaces 32 between adjacentapertures 30. As will be explained hereafter, the presence andconstruction of the interstitial spaces 32 are believed to play animportant role in the distribution performance of the applicator 10 andin turn the performance of the substance distributed. In the embodimentshown in FIG. 1, the applicator 10 also includes an optional cover 40releasably affixed to first side 21 so as to sealingly engage the firstsurface over and around the apertures 30 to occlude the apertures 30 andprevent premature dispensing or contamination of the product before theintended use. The cover may engage the first surface around theperiphery of individual apertures or around the periphery of thedelivery zone 31. Optional cover 40 may comprise a label withinstructions or other suitable indicia thereon.

[0017] Second side 22 is preferably free of apertures and is preferablysubstantially planar, although for some applications it may be desirableto include some surface topography (such as a series of smallprotrusions coinciding with the locations of reservoirs 50) at least inthe region underlying the delivery zone 31, to aid the user in orientingthe applicator properly. The first surface also preferably includes aoptional grasping portion 24 which is substantially free of aperturesand is preferably located adjacent to one edge of the applicator. Forsome application configurations, it may be desirable to include a seconddelivery zone remotely from the first delivery zone, either elsewhere onthe first surface or on the second surface of the applicator.

[0018] As shown more clearly in FIG. 2, the apertures 30 each extendinwardly of the first surface 21 into the interior 23 of the sheet ofmaterial 20 to form corresponding reservoirs 50 to contain a substance60 prior to use. Suitable substances for use with the applicators of thepresent invention will be described in greater detail hereafter.Multiple substances may be employed in separate apertures and/orreservoirs, such that they remain segregated prior to applicator use butare co-mingled during use. This may be particularly useful wherein it isdesired to prevent reactions between components prior to use andcorresponding degradation or exhaustion of the active ingredients. Also,it may be desirable to include one or more “empty” apertures/reservoirsto either add air to the dispensed product and/or to act as a receivingreservoir to remove excess product from the target surface.

[0019]FIG. 2 also illustrates the geometrical relationship between theapertures 30, reservoirs 50, interstitial spaces 32, and the sheetmaterial 20. The apertures, which may be of any desired size and shape,each have a peripheral edge which lies in the plane of the first surface21 and defines the boundary of the aperture. In the instance where thesheet of material comprises a cellular structure, the apertures aresubstantially larger than the average cell size of the material. Theinterstitial spaces 32 are thus defined as the portion of the firstsurface 21 located between the peripheral edges of adjacent apertures.The reservoirs are located inwardly of the apertures and comprises avoid within the interior of the sheet material. As with the apertures,the reservoirs are substantially larger than the average cell size ofthe material when the sheet of material is formed from a cellularstructure. The reservoirs may or may not have the same cross-sectionalshape in a direction parallel to the first surface 21 as that of theapertures 30. The sheet of material has an overall thickness T which isdefined as the average distance between the opposing first and secondsurfaces 21 and 22 measured in a direction substantially normal to thefirst surface. In the instance wherein the surfaces are co-planar, thethickness T is perpendicular to both surfaces, and where non-planarsurfaces are involved the planes of respective surfaces are defined asan average position of a representative plane passing through thesurface topography.

[0020] The use of one or more discrete reservoirs as opposed to agenerally porous substance-impregnated material, provides a morecontrolled dosing functionality for the applicators of the presentinvention. The reservoir geometry and volume may be designed as desiredfor ultimate capacity and also rate of delivery, whether in thepreferred pre-loaded configuration where the applicator is manufacturedand sold with the product included or where the applicator ismanufactured independently of the product and the consumer applies thesubstance to the applicator.

[0021] In a given applicator, the delivery zone may include a pluralityof apertures having differing sizes and/or shapes in either a regularpattern or an irregular pattern, and reservoirs need not also be filledto the same level or have the same capacity. Apertures can be of anydesired cross-sectional shape at their intersection with the firstsurface, such as oval, elliptical, hexagonal, etc, but a circularcross-sectional shape is presently preferred.

[0022] The reservoirs 50 extend inwardly from the first surface to adepth t. Accordingly, since the reservoirs are formed as voids in thesheet of material 20, the material is a comparatively thick material onthe order of at least about 0.063-0.250 inches as compared to formingreservoirs in thin embossed materials such as polymeric films. The sheetof material 20 is formed from a material which is sufficientlyconformable to enable the first surface 21 to conform to irregulartarget surfaces, and is preferably resiliently conformable forapplication in a dynamic environment as the first surface passes overnon-planar and irregular surfaces. The material utilized for theapplicator is also deformable in the direction of thickness T to supplyand deliver the substance 60 to the target surface for application anddistribution. Deformation of the sheet of material 20 in such a mannereffectively reduces the volume of the reservoirs 50 in the region ofdeformation, thus expressing the substance from the reservoirs outwardlythrough the apertures 30 into contact with the target surface.

[0023] Compressive deformation in the context of the present invention,as described herein, is defined as a reduction in the dimension T of thematerial by application of an external force (or otherwise) such thatthe first and second surfaces become closer together and the interiordimension between them becomes smaller. This is to be distinguished fromother types of deformable structures wherein surfaces of the material orstructure are translated or rotated relative to each other to reduce theeffective thickness of the material. Such a thickness may be moreappropriately characterized as “caliper” rather than “thickness”, as the“caliper” of such a material will be by definition greater than the“thickness” of the material from which it is made. An example of such astructure would be a three-dimensionally-embossed film which has aplurality of dimples or ribs formed therein. The film initially has acertain thickness or gauge, but after deformation out of the plane ofthe material the film has a caliper increase due to the dimensions ofthe ribs or dimples. Such a material may undergo a dimensional reductionin a plane normal to the plane of the material, but only via thedeformation or destruction of the out-of-plane surfaces and structures.In structures and materials of the present invention, the caliper andthickness are substantially equivalent dimensions as any deviations fromsurface planarity in the vicinity of the delivery zone areinsignificant. Accordingly, as the material itself compresses under theinfluence of an external force the first and second surfaces move towardone another without rotating or otherwise distorting the geometry of thesheet material.

[0024] Without wishing to be bound by theory, it is believed that theuse of a comparatively thick substantially planar material withreservoirs formed into the material rather than the use of acomparatively thin material which is formed into a non-planar structureprovides an applicator which allows application forces to be moreuniformly transferred to the target surface for a more uniform substancedistribution. This is particularly important when the applied forces maybe more discretely applied, such as by one or more fingers spaced apart,as for most scenarios it is desired to not have the resulting productdistribution mirror the pattern of the applied forces. For example, ifone holds the applicator pad as shown in FIG. 3 it is desired to form asubstantially uniform coating of the substance upon the target surfacerather than four streaks of product corresponding to the location of thefour fingers.

[0025] Another important characteristic for applicators of the presentinvention is the ability of the material to “glide” across the targetsurface without rolling up or otherwise becoming distorted. This alsohelps to ensure a comparatively even substance distribution on thetarget surface. Accordingly, selection of suitable applicator materialsshould account for not only the substance characteristics in terms ofshear and other properties, but also the coefficient of friction of thematerial and the target surface.

[0026] The sheet material 20 may be unitary in nature, constructed froma single monolithic piece of material, or may comprise two or morelayers or plies of material. In addition, it may be desirable to formthe apertures and reservoirs in one layer of material, completelypenetrating the sheet of material, and then laminating another layer ofsimilar or diverse composition onto the second surface of the firstpiece of material to close the inward end of the reservoirs.

[0027] A presently preferred construction utilizes a polyethylene/EVAfoam pad with multiple heat-embossed product reservoirs/apertures in onesurface. However, a wide variety of other materials are contemplated asbeing within the scope of the present invention having suitable physicaland/or chemical properties for the intended substance and intendedtarget surface. The foam pad may be cut to the desired shape with apress and rule die, or other suitable means. The substance may beinjected, doctored, or otherwise supplied to the reservoirs. Theapplicator may be of any desired size and shape, although the shapedepicted in FIGS. 1-3 in dimensions of approximately 2.7″×2.4″×0.125″thick has proven satisfactory in use, with 38 equally sized and spacedreservoirs forming an ellipse having an approximate major dimension ofabout 1.5 to 2.0 inches and a minor dimension of about 0.9 to 1.3 inchesand delivering approximately 0.4 grams of antiperspirant composition(such as that described below). A presently preferred aperture size isbetween about 0.100 and about 0.150 inches in diameter, with a circularcross-section, an edge-to-edge spacing of between about 0.050 and about0.110 inches, with a substantially straight-walled reservoir of similarcross-section extending inwardly therefrom.

[0028]FIG. 6 depicts another embodiment of the present invention in theform of an applicator 200 having dimensions of approximately2.7″×2.4″×0.125″ thick, which has proven satisfactory in use. Applicator200 has 8 equally sized and spaced slot type reservoirs 210 positioneddiagonally at 45° within an ellipse area 220 having an approximate majordimension of about 1.5 to 2.0 inches and a minor dimension of about 0.9to 1.3 inches and delivering approximately 0.4 grams of antiperspirantcomposition (such as that described below). A presently preferred slottype reservoir 210 for applicator 200 has a length between about 0.578and about 0.473 inches, a width between about 0.100 and about 0.080inches, with a slot type cross-section with rounded ends, anedge-to-edge spacing between reservoirs 210 of between about 0.220 andabout 0.080 inches, with a substantially straight-walled reservoir ofsimilar cross-section extending inwardly therefrom between about 0.125and about 0.080 inches in depth.

[0029]FIG. 7 depicts another embodiment of the present invention in theform of an applicator 300 having dimensions of approximately2.7″×2.4″×0.125″ thick, which has proven satisfactory in use. Applicator300 has 9 aperture-channel type reservoirs of varying configurationpositioned within an ellipse area 360 having an approximate majordimension of about 1.5 to 2.0 inches and a minor dimension of about 0.9to 1.3 inches and delivering approximately 0.4 grams of antiperspirantcomposition (such as that described below). Applicator 300 has avariation of: 2-aperture-channel reservoirs 310 having two apertures 340connected by a single channel 350, 3-aperture-channel reservoirs 320having three apertures 340 connected by two channels 350, and4-aperture-channel reservoirs 330 having four apertures 340 connected bythree channels 350. A presently preferred aperture 340 is between about0.165 and about 0.135 inches in diameter, with a circular cross-section.A presently preferred channel 350 is between about 0.055 and about 0.045inches in width, with a rectangular cross-section. A presently preferredspacing between the center of adjoining apertures 340 is between about0.280 and about 0.200 inches in length. Edge-to-edge spacing between theapertures 340 is between about 0.095 and about 0.065 inches. Reservoirsare substantially straight-walled of similar cross-section extendinginwardly therefrom between about 0.125 and about 0.080 inches in depth.

[0030]FIG. 8 depicts another embodiment of the present invention in theform of an applicator 400 having dimensions of approximately2.7″×2.4″×0.125″ thick, which has proven satisfactory in use. Applicator400 has 7 aperture-channel type reservoirs of varying configurationpositioned diagonally at 45° within an ellipse area having anapproximate major dimension of about 1.5 to 2.0 inches and a minordimension of about 0.9 to 1.3 inches and delivering approximately 0.4grams of antiperspirant composition (such as that described below).Applicator 400 has a variation of: 3-aperture-channel reservoirs 410having three apertures 440 connected by two channels 450,4-aperture-channel reservoirs 420 having four apertures 440 connected bythree channels 450, and 5-aperture-channel reservoirs 430 having fiveapertures 440 connected by four channels 450. A presently preferredaperture 440 is between about 0.165 and about 0.135 inches in diameter,with a circular cross-section. A presently preferred channel 450 isbetween about 0.055 and about 0.045 inches in width, with a rectangularcross-section. A presently preferred spacing between the center ofadjoining apertures 440 is between about 0.280 and about 0.200 inches inlength. Edge-to-edge spacing between the apertures 440 is between about0.095 and about 0.065 inches. Reservoirs are substantiallystraight-walled of similar cross-section extending inwardly therefrombetween about 0.125 and about 0.080 inches in depth.

[0031] For a given product, an applicator design should be optimized tominimize premature dispensing and to maximize intentional-delivery ofthe desired product. A method which is believed to prevent prematuredispensing of the desired product is to maximize the surface area of thereservoirs to which the product will adhere. The product typically hasan affinity to the applicator surface; therefore, the product has atendency to remain within the reservoirs. However, increasing thesurface area of the reservoirs also decreases the amount of product thatwill be delivered intentionally later by the consumer. The propensity ofthe product to stay in the reservoir due to reservoir surface area, andthe corresponding propensity of the product to be intentionallydelivered by the consumer, are inversely related but not necessarilylinearly proportional. Without wishing to be bound by theory, it isbelieved that as the surface area of a reservoir is increased for aconstant reservoir volume and depth, there results a reduction inpremature dispensing but also a corresponding, but not necessarilylinearly, proportional reduction in intentionally-delivered product.Such theory may be discussed in reference to an aspect ratio defined andcalculated as the [surface area of the reservoir]/[surface area of acylindrical reservoir having an equal volume and depth]. It is believedthat as the aspect ratio is increased, there results a reduction inpremature dispensing but also a corresponding, but not necessarilylinearly, proportional reduction in intentionally-delivered product. Indetermining the optimal applicator design for a given product, thisaspect ratio may be used to compare various designs. For the embodimentsillustrated in FIGS. 6, 7, and 8 such a method of optimization wasutilized and it was found that an aspect ratio ranging from about 1 toabout 5 has proven satisfactory in use for the products describedherein.

[0032] As mentioned previously, it is presently preferred that thematerials utilized in the present invention are not only compressible inthe thickness direction but also conformable in the planar direction soas to accommodate various target surface topographies in use. It is alsopreferred that suitable sheet materials also be resilient, preferablyboth in terms of their compressibility and in terms of their bendingconformability. Resilience is defined consistent with its everydaymeaning, as evidenced by Webster's Ninth New Collegiate Dictionary, as“the capability of a strained body to recover its size and shape afterdeformation caused esp. by compressive stress.” Resilience of thematerial causes it to tend to return to its undeformed, preferablysubstantially planar state and original thickness after compressive orbending forces, thereby enabling it to conform to various targetsurfaces and yet maintain target surface contact for proper substancedistribution.

[0033] Preferred material properties, as well as the properties of thepresently preferred material, Volara 2E0 ⅛″ PE/EVA polyethylene/ethylenevinyl acetate copolymer (12%VA) fine-cell crosslinked polymer foam,commercially available from Voltek, 100 Shepard Street, Lawrence, Mass.01843, are presented in the table below: PROPERTIES Volara 2EO ⅛″Preferred Range Test Method Thickness in. 0.125 0.063-0.250 ASTM D-3575Density lbs/cu ft. 2 nominal 2-6 ASTM D-3575 Tensile Str psi (MD) 55min.  40-200 ASTM D-3575 Break Elongation % 140 min. 100-350 ASTM D-3575(MD) Tear Resistance 7 min. 4.5-30  ASTM D-3575 lb/in (MD) CompressionStr. Psi @ 25% deflection 2.5 min. 1.5-15  ASTM D-3575 @ 50% deflection9 min.  4-25 ASTM D-3575 Compression set % 30 max.  0-50 ASTM D-3575

[0034] To quantify stiffness, a suitable method is TAPPI T489 om-92,Stiffness of paper and paperboard (Taber-type stiffness tester). Resultsare in gram centimeters or Taber units. Equipment used; Taber V-5 model150B Stiffness Tester. Note: NO weight added and results measured at 15degrees displacement. Actual Data: Material ⅛″ caliper (Voltek#) MD CDpolyethylene (2A) 65 gm cm 2 PE/EVA 12% VA (2EO) 47 34 PE/EVA 18% VA(2G) 41 32

[0035] While Volara 2EO is presently preferred material, alternateVolara grades and alternate foam materials such as open cell foam,non-crosslinked foam, foam with a range of cell sizes, alternate resins,100% polyethylene, polystyrene, polypropylene, rubber, urethanes, otherethylene copolymers, propylene copolymers, and other synthetic materialshaving similar material properties could be used. Note, however, forsome applications materials being substantially stiffer or softer may bepreferred.

[0036] In the embodiment shown in FIGS. 1 and 2, the reservoirs havewalls which are substantially normal to the first surface of the sheetof material. However, for certain product formulations of the substanceto be delivered to the target surface it may be desirable to providereservoir and aperture geometries wherein the reservoirs have sidewallsat angles other than 90 degrees, such as, for example, funnel-shapedtapered aperture/reservoir geometries wherein the reservoir narrows withincreasing distance inwardly from the first surface or “undercut”aperture geometries where the reservoir widens with increasing distanceinwardly from the first surface. Reservoirs may also be formed withsubstantially planar bottoms (the portion located distally from theapertures and within the interior of the sheet of material), or thebottoms of the reservoirs may be radiused, depending upon themanufacturing method of choice and the nature of the substances andsheet materials employed.

[0037] In addition, it is preferred that when the sheet of materialcomprises a porous material the reservoirs include some suitable meansof preventing substance migration into the matrix of the sheet material.A presently preferred method of preventing such migration is to utilizea closed-cell foam material. However, such means may include animpermeable coating or may be some other means of rendering thereservoir walls impermeable such as thermally melting the porous sheetmaterial during formation of the apertures and reservoirs to form a“skin”. Additional layers or coatings of polymers such as PET, nylon,etc. may be employed on the reservoir walls, the second side 21 of theapplicator, or other regions where it is desired to limit substancepenetration of the material. Any such treatments or approaches would betailored to suit the particular combination of substance and applicatormaterial(s). For some applications, it may also be desirable that theinner surfaces of the reservoir(s) and aperture(s) have some degree ofsurface topography to aid in anchoring the substance. Internalstructures such as protrusions, “bosses”, peripheral rings, etc., mayalso be desirable to aid in substance retention. Various reservoirconfigurations may be employed without being limited to the apertureshape or the overall shape of the applicator, and may be tailored asdesired to facilitate substance retention and/or dispensing.

[0038]FIG. 3 provides an illustration of an applicator 10 in accordancewith the present invention being utilized to apply a substance to atarget surface. As shown in FIG. 3, the applicator 10 is manuallygrasped by the hand 80 of a user, typically by pinching the applicatorbetween the thumb and palm with the fingers contacting the secondsurface 22 in the vicinity of apertures 30 and the thumb contacting thegrasping portion 24. The user then brings the delivery zone 31 of theapplicator 10 into contact with a target surface 90, which may have anysurface topography and may be planar or non-planar, and applies a forcehaving at least a normal force vector component in a direction F whichis substantially normal to the target surface 90. A tangential force orforce vector component exerted in direction D is applied, preferablysimultaneously with the application of normal force F, to move theapplicator across the target surface 90 to apply a substantially uniformcoating of the substance 60 to the target surface, preferably in aregion substantially conforming to the scope of the delivery zone 31 andto the distance travelled. The normal and tangential forces may combinein such a manner as to define a total force vector which defines anangle between about 0 and about 90 degrees from the plane of the firstsurface. Such a manner of application provides for dispensing of thesubstance during the distribution phase of the process, rather than thetypical extrusion or dispensing of substances followed by thedistribution phase.

[0039] In a dynamic application environment such as that depicted inFIG. 3, in contrast with a “static” application scenario with norelative translational movement, it is believed that the relationshipbetween the apertures (where a plurality are utilized) and the spacesbetween them is an important consideration in the design of suitableapplicator geometries for particular substances. Each aperture has aperipheral edge which is surrounded by a portion of the first surface ofthe sheet material. As the sheet material, at least the first surfacethereof, is preferably substantially planar, each aperture is thussurrounded by a substantially planar ring of material which contacts thetarget surface around the aperture and which provides a “rub-in” surfaceto distribute the substance on the target surface. Where the substanceis or becomes flowable at the time of application, this ring of materialforms a gasket-like surface which aids in uniformly distributing productby encouraging the outward flow of product from the apertures.Optionally, if desired a certain amount of surface texture, such asmicrotexture, may be applied to the portions of the first surfacebetween and/or adjacent to the apertures to aid in the distributionfunction and/or the aesthetics of the application function in terms ofskin feel, etc.

[0040] The applicators of the present invention depicted in FIGS. 1-3have corresponding plural apertures and plural reservoirs, andpreferably a 1:1 ratio of apertures to reservoirs. However, othercombinations of apertures and reservoirs are also possible, such asmultiple reservoirs supplying each aperture or multiple aperturessupplied by a single reservoir. FIGS. 4 and 5 depict such an alternateembodiment. The applicator 110 of FIGS. 4 and 5 has a sheet of material120 similar to the sheet of material 20 of FIGS. 1-3, but unlike theapplicator 10 the applicator 110 has a plurality of apertures 130 whichextend inwardly from the first surface 121 through the interior 123 ofthe sheet of material all the way through the second side 122, such thata completely unobstructed passageway is provided through the sheet ofmaterial 120. In such an embodiment, the sheet of material has athickness T which is equivalent to the distance t (omitted for clarity).The apertures 130 form a delivery zone 131, are separated byinterstitial spaces 132, and are preferably but optionally covered by aremovable cover 140 which may have instructions or other suitableindicia thereon. The applicator 110 also includes a backing sheet 170which is peripherally joined to the sheet of material 120 via a heatseal 125 or other suitable sealing technique, the backing sheet 170cooperating with the seal 125, sheet of material 120, and cover 140 toform at least one, and preferably only one, reservoir 150 for containinga product 160 therein.

[0041] Another variation would include the use of a single largereservoir in an embodiment similar to that of FIG. 1, but including aplurality of “islands” protruding from the floor of the reservoir toprovide a surface-contacting rub-in surface analogous to the network ofinterstitial spaces formed between multiple discrete apertures as shownin FIG. 1.

[0042] The apertures of the applicators of the present invention may besealed prior to use in other ways than the use of a cover/label such ascover 40/140. For example, applicators may be sealed/bonded to oneanother in face-to-face or back-to-back relationship such that onesurface of one applicator obstructs the apertures of the next. Otherpossible orientations include face-to-face orientations with deliveryzones non-aligned and overlying other portions of the first surface,face-to-back, etc., and pairs of such materials can be packaged in abarrier film (foil laminate, metallized polyester, etc.) to form aconvenient package.

[0043] The applicator of the present invention comprises a packageddelivery system having a shear force delivery means. Other examples ofsuch delivery systems are well known in the art, and typically comprisean enclosed package or container having an attached shear force deliverymeans such as a perforated cap or other perforated surface. Shear forcedelivery means subject the delivered substance to shear forces whichcounteract the tendencies of the substance to agglomerate and/or remainin comparatively large or thick deposits and spread across the targetsurface. The application of shear force in combination with thesubstance delivery process is particularly important when the rheologyand other product characteristics change under the influence of shearforces, such as the substance becoming more flowable under shear.Additional discussion of substance rheology follows hereafter.

[0044] Typical shear force delivery means include any ridged or flexiblesurface, preferably a ridged surface, suitable for attachment to apackage or other product, and which has a plurality of openings,apertures or orifices extending through the thickness of the ridged orflexible surface through which the composition can flow to the intendedsite of application. However, in accordance with the present inventionthe applicators described herein provide delivery and distributionfunctionality meeting or exceeding that of other shear force deliverymeans in a convenient, economical, easy-to-use form.

[0045] 2. Representative Compositions.

[0046] In the present invention, the term “substance” can mean aflowable substance which is substantially non-flowing prior to deliveryto a target surface. “Substance” can also mean a material which doesn'tflow at all, such as a fibrous or other interlocking material.“Substance” may mean a fluid or a solid. “Substance” is defined in thisinvention as any material capable of being held in openthree-dimensional recesses of the applicator material in the absence ofexternal forces other than those of gravity. While substances which aresubstantially non-flowable prior to delivery are presently preferred,substances which are flowable or have greater flowability may be foundsuitable for use in the present invention wherein overwraps, seals, orthe like provide for sufficient substance retention/protection prior touse. Adhesives, electrostatics, mechanical interlocking, capillaryattraction, surface adsorption, van der Waals forces, and friction, forexample, may be used to hold the substances in the apertures and/orreservoirs. The substances are intended to be at least partiallyreleased therefrom when exposed to contact with external surfaces whenthe applicator is subjected to externally-applied compressive forces. Ofcurrent interest in the present invention include substances such asgels, pastes, creams, lotions, foams, powders, agglomerated particles,prills, microencapsulated liquids, waxes, suspensions, liquids, andcombinations thereof.

[0047] The spaces in the three dimensional structure of the presentinvention are normally open; therefore it is desirable to havesubstances stay in place and not run out of the structure without anactivation step. Accordingly, substances which are preferred are capableof staying within the apertures and/or reservoirs even in the absence ofan overwrap. The activation step utilized in accordance with the presentinvention is deformation of the three dimensional structure bycompression, which overcomes the tendencies of the substance to remainwithin the applicator.

[0048] Preferred substances include those which may be liberated fromthe applicator without the need for solvents (including water, etc.) inorder to provide for a ready-to-use device. However, such preferenceshould not preclude the use of otherwise suitable substances merelybecause some degree of solvent use may be necessary. Suitable substancesmay be anhydrous, and perform satisfactorily and desirably in theabsence of water.

Antiperspirant/Deodorant Compositions

[0049] The antiperspirant and deodorant substances for use in theapplicator of the present invention are non-flowing compositions whichare intended for topical application to the underarm or other suitableareas of the skin. These deodorant and antiperspirant compositionscomprise an active ingredient and a suspending or thickening agentincorporated into a suitable liquid carrier. In this context, the term“active” refers to antiperspirant actives, deodorant actives, orfragrances, and include any known or otherwise safe and effectiveantiperspirant, deodorant, or fragrance active material. The terms“antiperspirant active” and “deodorant active” specifically refers totopical materials which can prevent or eliminate malodors and/orperspiration wetness. The term “fragrance” as used herein specificallyrefers to any topical material which covers or masks malodors resultingfrom perspiration, or which otherwise provides the composition with thedesired perfumed aroma.

[0050] Antiperspirant Active

[0051] The antiperspirant compositions for use in the applicator of thepresent invention comprise antiperspirant active suitable forapplication to human skin. The antiperspirant active may be solubilizedin the antiperspirant compositions or may be suspended as an undissolvedor precipitated solid. The concentration of the antiperspirant active inthe antiperspirant compositions should be sufficient to provide thedesired odor and wetness control from the antiperspirant compositionselected.

[0052] The antiperspirant compositions described herein compriseantiperspirant active at concentrations of from about 0.5% to about 60%,preferably from about 0.5% to about 50%, more preferably from about 5%to about 35%, by weight of the selected antiperspirant composition. Allsuch weight percentages are calculated on an anhydrous metal salt basisexclusive of water and any complexing agents such as glycine, glycinesalts, or other complexing agents.

[0053] The antiperspirant active for use in the antiperspirantcompositions described herein include any compound, composition or othermaterial having antiperspirant activity. Preferred antiperspirantactives include the astringent metallic salts, especially the inorganicand organic salts of aluminum, zirconium and zinc, as well as mixturesthereof. Particularly preferred are the aluminum and zirconium salts,such as aluminum halides, aluminum hydroxyhalides, zirconyl oxyhalides,zirconyl hydroxyhalides, and mixtures thereof.

[0054] Preferred aluminum salts for use in the antiperspirantcompositions include those which conform to the formula:

Al₂(OH)_(a)Cl_(b) .xH₂O

[0055] wherein a is from about 2 to about 5; the sum of a and b is about6; x is from about 1 to about 6; and wherein a, b, and x may havenon-integer values. Particularly preferred are the aluminumchlorhydroxides referred to as “⅚ basic chlorhydroxide”, wherein a=5,and “⅔ basic chlorhydroxide”, wherein a=4. Processes for preparingaluminum salts are disclosed in U.S. Pat. No. 3,887,692, Gilman, issuedJun. 3, 1975; U.S. Pat. No. 3,904,741, Jones et al., issued Sep. 9,1975; U.S. Pat. No. 4,359,456, Gosling et al., issued Nov. 16, 1982; andBritish Patent Specification 2,048,229, Fitzgerald et al., publishedDec. 10, 1980, which disclosures are incorporated herein by reference.Mixtures of aluminum salts are described in British Patent Specification1,347,950, Shin et al., published Feb. 27, 1974, which description isalso incorporated herein by reference.

[0056] Preferred zirconium salts for use in the antiperspirantcompositions include those which conform to the formula:

ZrO(OH)_(2-a)Cl_(a) .xH₂O

[0057] wherein a is any number having a value of from about 0 to about2; x is from about 1 to about 7; and wherein a and x may both havenon-integer values. These zirconium salts are described in BelgianPatent 825,146, Schmitz, issued Aug. 4, 1975, which description isincorporated herein by reference. Particularly preferred zirconium saltsare those complexes which additionally contain aluminum and glycine,commonly known as ZAG complexes. These ZAG complexes contain aluminumchlorhydroxide and zirconyl hydroxy chloride conforming to the abovedescribed formulas. Such ZAG complexes are described in U.S. Pat. No.3,679,068, Luedders et al., issued Feb. 12, 1974; Great Britain PatentApplication 2,144,992, Callaghan et al., published Mar. 20, 1985; andU.S. Pat. No. 4,120,948, Shelton, issued Oct. 17, 1978, whichdescriptions are incorporated herein by reference.

[0058] The antiperspirant active may be formulated as particulate solidsin the form of dispersed solid particles having a preferred averageparticle size or diameter of less than about 100 μm, more preferablyfrom about 2 μm to about 50 μm, even more preferably from about 0.4 μmto about 40 μm.

[0059] The antiperspirant compositions described herein may comprisesolubilized antiperspirant active, preferably solubilized antiperspirantactive in an anhydrous system. The concentration of solubilizedantiperspirant active in the antiperspirant compositions preferablyranges from about 0.1% to 35%, more preferably from about 0.5% to about25%, even more preferably from about 1% to about 17%, even morepreferably from about 6% to about 17%, by weight of the selectedantiperspirant composition (weight percentages calculated on ananhydrous metal salt basis exclusive of water and any complexing agentssuch as glycine, glycine salts, or other complexing agents).

[0060] Deodorant Active

[0061] The deodorant compositions for use in the applicator of thepresent invention comprise deodorant active at concentrations rangingfrom about 0.001% to about 50%, preferably from about 0.01% to about20%, more preferably from about 0.1% to about 10%, even more preferablyfrom about 0.1% to about 5%, by weight of the selected deodorantcomposition. These deodorant actives can include any known or otherwisesafe and effective deodorant active suitable for topical application tohuman skin.

[0062] Deodorant actives suitable for use in the deodorant compositionsdescribed herein include any topical material that is known for or isotherwise effective in preventing or eliminating malodor associated withperspiration. These deodorant actives are typically antimicrobial agents(e.g., bacteriocides, fungicides), malodor-absorbing material, orcombinations thereof.

[0063] Preferred deodorant actives are antimicrobial agents,non-limiting examples of which include cetyl-trimethylammonium bromide,cetyl pyridinium chloride, benzethonium chloride, diisobutyl phenoxyethoxy ethyl dimethyl benzyl ammonium chloride, sodium N-laurylsarcosine, sodium N-palmethyl sarcosine, lauroyl sarcosine, N-myristoylglycine, potassium N-lauryl sarcosine, trimethyl ammonium chloride,sodium aluminum chlorohydroxy lactate, triethyl citrate, tricetylmethylammonium chloride, 2,4,4′-trichlorio-2′-hydroxy diphenyl ether(triclosan), 3,4,4′-trichlorocarbanilide (triclocarban), diaminoalkylamides such as L-lysine hexadecyl amide, heavy metal salts of citrate,salicylate, and piroctose, especially zinc salts, and acids thereof,heavy metal salts of pyrithione, especially zinc pyrithione, zincphenolsulfate, farnesol, and combinations thereof.

[0064] Other deodorant actives include odor-absorbing materials such ascarbonate and bicarbonate salts, including alkali metal carbonates andbicarbonates, ammonium and tetraalkylammonium. Preferred are sodium andpotassium salts of such odor-absorbing materials.

[0065] Fragrance

[0066] Fragrances suitable for use herein include any topical materialthat is known for or is otherwise effective in masking malodorassociated with perspiration, or which otherwise provides the substancecompositions with the desired perfumed aroma. These fragrances includeany perfume or perfume chemical suitable for topical application to theskin. The fragrance material can be used alone or in combination withthe antiperspirant active or deodorant active. Concentrations of thefragrance material generally range from about 0.001% to about 50%,preferably from about 0.01% to about 20%, more preferably from about0.1% to about 10%, even more preferably from about 0.1% to about 5%, byweight of the selected antiperspirant or deodorant composition.

[0067] The concentration of the fragrance in the antiperspirant ordeodorant compositions should be effective to provide the desired aromacharacteristics or to mask malodor, wherein the malodor is inherentlyassociated with the composition itself or is associated with malodordevelopment from human perspiration. Also, the fragrance and whatevercarriers accompany it should not impart excessive stinging to the skin,especially broken or irritated skin, at the levels previously disclosed.The fragrance will typically be in the form of water insoluble perfimesthat are solubilized in the antiperspirant or deodorant compositionsdescribed herein.

[0068] Fragrances are made by those skilled in the art in a wide varietyof fragrances and strengths. Typical fragrances are described inArctander, Perfume and Flavour Chemicals (Aroma Chemicals), Vol. I andII (1969); and Arctander, Perfume and Flavour Materials of NaturalOrigin (1960). U.S. Pat. No. 4,322,308 and U.S. Pat. No. 4,304,679, bothincorporated herein by reference, disclose fragrance components asgenerally including, but are not limited to, volatile phenolicsubstances (such as iso-amyl salicylate, benzyl salicylate, and thymeoil red); essence oils (such as geranium oil, patchouli oil, andpetitgrain oil); citrus oils; extracts and resins (such as benzoin siamresinoid and opoponax resinoid); “synthetic” oils (such as Bergamot 37and 430, Geranium 76 and Pomeransol 314); aldehydes and ketones (such asβ-methyl naphthyl ketone, p-t-butyl-A-methyl hydrocinnamic aldehyde andp-t-amyl cyclohexanone); polycyclic compounds (such as coumarin andβ-naphthyl methyl ether); esters (such as diethyl phthalate, phenylethylphenylacetate, non-anolide-1:4). Fragrances also include esters andessential oils derived from floral materials and fruits, citrus oils,absolutes, aldehydes, resinoides, musk and other animal notes (e.g.,natural isolates of civet, castoreum and musk), balsamic, etc. andalcohols (such as dimyrcetol, phenylethyl alcohol and tetrahydromuguol).Examples of such components useful as fragrances herein include decylaldehyde, undecyl aldehyde, undecylenic aldehyde, lauric aldehyde, amylcinnamic aldehyde, ethyl methyl phenyl glycidate, methyl nonylacetaldehyde, myristic aldehyde, nonalactone, nonyl aldehyde, octylaldehyde, undecalactone, hexyl cinnamic aldehyde, benzaldehyde,vanillin, heliotropine, camphor, para-hydroxy phenolbutanone, 6-acetyl1,1,3,4,4,6 hexamethyl tetrahydronaphthalene, alpha-methyl ionone,gamma-methyl ionone, and amyl-cyclohexanone and mixtures of thesecomponents.

[0069] Other suitable fragrances are those which mask or help to maskodors associated with perspiration (hereinafter referred to as odormasking fragrances), some non-limiting examples of which are describedin U.S. Pat. No. 5,554,588, U.S. Pat. No. 4,278,658, U.S. Pat. No.5,501,805, and EP Patent Application 684 037 A1, all of which areincorporated herein by reference in their entirety. Preferred odormasking fragrances are those which have a Deodorant Value of at leastabout 0.25, more preferably from about 0.25 to about 3.5, even morepreferably from about 0.9 to about 3.5, as measured by the DeodorantValue Test described in EP Patent Application 684 037 A1.

[0070] The fragrance for use herein may also contain solubilizers,diluents, or solvents which are well known in the art. Such materialsare described in Arctander, Perfume and Flavour Chemicals (AromaChemicals), Vol. I and II (1969). These materials typically includesmall amounts of dipropylene glycol, diethylene glycol, C₁-C₆ alcohols,and/or benzyl alcohol.

[0071] Suspending or Thickening Agent

[0072] The antiperspirant and deodorant compositions for use in theapplicator of the present invention comprise a suspending or thickeningagent to help provide the compositions with the desired viscosity orproduct hardness, or to otherwise help suspend any dispersed solids orliquids within the compositions. Suitable suspending or thickeningagents include any material known or otherwise effective in providingsuspending or thickening properties to the compositions, or whichotherwise provide structure to the final product forms. These suspendingor thickening agents include gelling agents, and polymeric ornonpolymeric or inorganic thickening or viscosifying agents. Suchmaterials will most typically include organic solids, silicone solids,crystalline or other gellants, inorganic particulates such as clays orsilicas, or combinations thereof.

[0073] The concentration and type of the suspending or thickening agentselected for use in the antiperspirant and deodorant compositions willvary depending upon the desired product form, viscosity, and hardness.For most suspending or thickening agents suitable for use in thecompositions described herein, the concentration of such suspending orthickening agents will most typically range from about 0.1% to about35%, more typically from about 0.1% to about 20%, by weight of theselected antiperspirant or deodorant composition.

[0074] Suitable gelling agents for use as suspending or thickeningagents herein include, but are not limited to, fatty alcohols, esters offatty alcohols, fatty acids, hydroxy fatty acids, esters and amides offatty acids or hydroxy fatty acids, ethers of fatty acids, ethoxylatedfatty alcohols, ethoxylated fatty acids, waxes, cholesterolic materials,dibenzylidene alditols, lanolinolic materials, other amide and polyamidegellants, and corresponding salts thereof. All such gellants preferablyhave a fatty alkyl moiety having from about 14 to about 60 carbon atoms,more preferably from about 20 to about 40 carbon atoms, and which may besaturated or unsaturated, substituted or unsubstituted, branched orlinear or cyclic.

[0075] The term “substituted” as used herein refers to chemical moietiesknown or otherwise effective for attachment to gellants or othercompounds. Such substituents include those listed and described in C.Hansch and A. Leo, Substituent Constants for Correlation Analysis inChemistry and Biology (1979), which listing and description areincorporated herein by reference. Examples of such substituents include,but are not limited to, alkyl, alkenyl, alkoxy, hydroxy, oxo, nitro,amino, aminoalkyl (e.g., aminomethyl, etc.), cyano, halo, carboxy,alkoxyaceyl (e.g., carboethoxy, etc.), thiol, aryl, cycloalkyl,heteroaryl, heterocycloalkyl (e.g., piperidinyl, morpholinyl,pyrrolidinyl, etc.), imino, thioxo, hydroxyalkyl, aryloxy, arylalkyl,and combinations thereof.

[0076] The term “corresponding salts” as used herein refers to cationicsalts formed at any acidic (e.g., carboxyl) group, or anionic saltsformed at any basic (e.g., amino) group, either of which are suitablefor topical application to human skin. Many such salts are known in theart, examples of which are described in World Patent Publication87/05297, Johnston et al., published Sep. 11, 1987, which description isincorporated herein by reference.

[0077] Suitable fatty alcohols for use in the antiperspirantcompositions described herein include those compounds that are solidsunder ambient conditions and that have from about 8 to about 40 carbonatoms. These gelling agents are wax-like materials which are mosttypically used at concentrations ranging from about 0.1% to about 25%,preferably from about 3% to about 20%, by weight of the selectedantiperspirant composition. Specific examples of fatty alcohols for useherein include, but are not limited to, cetyl alcohol, myristyl alcohol,stearyl alcohol, and the Unilins available from Petrolite as Unilin 550,Unilin 700, Unilin 400, Unilin 350, and Unilin 325.

[0078] Nonlimiting examples of suitable esters of fatty alcohols for usein the antiperspirant compositions described herein includetri-isostearyl citrate, ethyleneglycol di-12-hydroxystearate,tristearylcitrate, stearyl octanoate, stearyl heptanoate,trilaurylcitrate.

[0079] Suitable fatty acids for use in the antiperspirant and deodorantcompositions described herein include, but are not limited to, fattyacid and hydroxy or alpha hydroxy fatty acids having from about 10 toabout 40 carbon atoms, examples of which include 12-hydroxystearic acid,12-hydroxylauric acid, 16-hydroxyhexadecanoic acid, behenic acid, eurcicacid, stearic acid, caprylic acid, lauric acid, isostearic acid,combinations thereof, and salts thereof. Some preferred examples offatty acids suitable for use herein are disclosed in U.S. Pat. No.5,429,816, issued to Hofrichter et al. on Jul. 4, 1995; and U.S. Pat.No. 5,552,136, issued to Motley on Sep. 3, 1996, both disclosures ofwhich are incorporated by reference herein. Some commercial examples offatty acids include, but are not limited to, Unicid 400, available fromPetrolite.

[0080] Nonlimting examples of salts of fatty acids for use in theantiperspirant and deodorant compositions described herein include thosecompounds wherein the fatty acid moiety has from about 12 to about 40carbon atoms, preferably from about 12 to about 22 carbon atoms, morepreferably from about 16 to about 20 carbon atoms, most preferably about18 carbon atoms. Suitable salt forming cations for use with thesegelling agents include metal salts such as alkali metals, e.g. sodiumand potassium, and alkaline earth metals, e.g. magnesium, and aluminum.Preferred are sodium and potassium salts, more preferably sodiumstearate, sodium palmitate, potassium stearate, potassium palmitate,sodium myristate, aluminum monostearate, and combinations thereof. Mostpreferred is sodium stearate.

[0081] Suitable ethoxylated gellants for use in the antiperspirantcompositions described herein include, but are not limited, Unithox 325,Unithox 400, Unithox 450, Unithox 480, Unithox 520, Unithox 550, Unithox720, and Unithox 750 (all of which are available from Petrolite), C20 toC40 pareth-3, and combinations thereof.

[0082] Suitable fatty acid esters for use in the antiperspirantcompositions described herein include ester waxes, monoglycerides,diglycerides, triglycerides and combinations thereof. Preferred are theglyceride esters. Nonlimiting examples of suitable ester waxes includingstearyl stearate, stearyl behenate, palmityl stearate, stearyloctyldodecanol, cetyl esters, cetearyl behenate, behenyl behenate,ethylene glycol distearate, ethylene glycol dipalmitate, and beeswax.Examples of commercial ester waxes include Kester waxes from KosterKeunen, Crodamol SS from Croda, and Demalcare SPS from Rhone Poulenc.Preferred are glyceryl tribehenate and other triglycerides, wherein atleast about 75%, preferably about 100%, of the esterified fatty acidmoieties of said other triglycerides each have from about 18 to about 36carbon atoms, and wherein the molar ratio of glyceryl tribehenate tosaid other triglycerides is from about 20:1 to about 1:1, preferablyfrom about 10:1 to about 3:1, more preferably from about 6:1 to about4:1. The esterified fatty acid moieties may be saturated or unsaturated,substituted or unsubstituted, linear or branched, but are preferablylinear, saturated, unsubstituted ester moieties derived from fatty acidmaterials having from about 18 to about 36 carbon atoms. Thetriglyceride gellant preferably has a preferred melting point of lessthan about 110° C., preferably between about 50° C. and 110° C.Preferred concentrations of the triglyceride gellants range from about4% to about 20%, more preferably from about 4% to about 10%, by weightof the selected antiperspirant composition. Specific examples ofpreferred triglyceride gellants include, but are not limited to,tristearin, hydrogenated vegetable oil, trihydroxysterin (Thixcin® R,available from Rheox, Inc.), rape seed oil, castor wax, fish oils,tripalmiten, Syncrowax® HRC and Syncrowax® HGL-C (Syncrowax® availablefrom Croda, Inc.). Other suitable glycerides include, but are notlimited to, glyceryl stearate and glyceryl distearate.

[0083] Suitable amide gellants for use in the antiperspirant anddeodorant compositions described herein include monoamide gellants,diamide gellants, triamide gellants, and combinations thereof,nonlimiting examples of which include cocoamide MEA (monoethanolamide),stearamide, oleamide, oleamide MEA, tallow amid monoethanolamide, andthe n-acyl amino acid amide derivatives described in U.S. Pat. No.5,429,816, issued to Hofrichter et al. on Jul. 4, 1995, whichdescription is incorporated herein by reference. Other suitable amidegelling agents are described in U.S. Pat. No. 5,429,816, and U.S. patentapplication Ser. No. 08/771,183, filed Dec. 20, 1996, which descriptionsare incorporated herein by reference. Concentrations of the amidegellants preferably range from about 0.1% to about 25%, more preferablyfrom about 1% to about 15%, even more preferably from about 1% to about10%, by weight of the selected antiperspirant or deodorant composition.

[0084] Other suitable gelling agents for use in the antiperspirant anddeodorant compositions described herein include waxes or wax-likematerials having a melt point of above 65° C., more typically from about65° C. to about 130° C., examples of which include, but are not limitedto, waxes such as beeswax, carnauba, baysberry, candelilla, montan,ozokerite, ceresin, hydrogenated castor oil (castor wax), syntheticwaxes, microcrystalline waxes. Castor wax is preferred within thisgroup. Other high melting point waxes are described in U.S. Pat. No.4,049,792, Elsnau, issued Sep. 20, 1977, which description isincorporated herein by reference.

[0085] Other suitable suspending or thickening agents for use in theantiperspirant compositions described herein include particulatesuspending or thickening agents such as clays and colloidal pyrogenicsilica pigments. Other known or otherwise effective particulatesuspending or thickening agents can likewise be used in the substancecompositions described herein. Concentrations of these suitableparticulate thickening agents preferably range from about 0.001% toabout 15%, more preferably from about 1% to about 15%, even morepreferably from about 1% to about 8%, by weight of the selectedantiperspirant composition. Colloidal pyrogenic silica pigments arepreferred, a common example of which includes Cab-O-Sil®, asubmicroscopic particulated pyrogenic silica.

[0086] Suitable clay suspending or thickening agents includemontmorillonite clays, examples of which include bentonites, hectorites,and colloidal magnesium aluminum silicates. These and other suitableclay suspending agents are preferably hydrophobically treated, and whenso treated will generally be used in combination with a clay activator.Non-limiting examples of suitable clay activators include propylenecarbonate, ethanol, and combinations thereof. The amount of clayactivator will typically range from about 25% to about 75% by weight ofthe clay, more typically from about 40% to about 60% by weight of theclay.

[0087] Liquid Carrier

[0088] The antiperspirant and deodorant compositions for use in theapplicator of the present invention comprise a liquid carrier that is aliquid under ambient conditions, wherein the liquid carrier comprisesone or more carrier liquid combinations or combinations of carrierliquids and dissolved carrier solids provided that any such combinationis in liquid form under ambient conditions.

[0089] Concentrations of the liquid carrier in the antiperspirant anddeodorant compositions will vary with the type of liquid carrierselected, the type of suspending or thickening agent used in combinationwith the liquid carrier, the type of product form desired, and so forth.Preferred concentrations of the liquid carrier ranges from about 1% toabout 90%, preferably from about 10% to about 80%, more preferably fromabout 20% to about 70%, by weight of the selected antiperspirant ordeodorant composition.

[0090] The antiperspirant and deodorant compositions described hereinmay be formulated as aqueous or anhydrous compositions. For an aqueousformulation, the compositions may further comprise from about 10% toabout 75% by weight of water, preferably from about 10% to about 60% byweight of water, even more preferably from about 15% to about 50%, byweight of water. For an anhydrous formulation, the compositions containless than about 10%, more preferably less than about 5%, even morepreferably less than about 3%, even more preferably less than about 1%,most preferably zero percent, by weight of free or added water.

[0091] The liquid carrier comprises one or more liquid carriers suitablefor topical application to human skin. These liquid carriers include anytopically safe and effective organic, silicone-containing orfluorine-containing, volatile or non-volatile, polar or non-polarcarrier liquid, provided that the resulting combination of carriermaterials form a solution or other homogenous liquid or liquiddispersion at the selected processing temperature of the composition.Processing temperatures for the antiperspirant and deodorantcompositions typically range from about 28° C. to about 250° C., moretypically from about 28° C. to about 110° C., and even more typicallyfrom about 28° C. to about 100° C.

[0092] The term “volatile” as used herein refers to those materialswhich have a vapor pressure as measured at 25° C. of from about 0.01mmHg to about 6 mmHg, preferably from about 0.02 mmHg to about 1.5 mmHg,and an average boiling point at one atmosphere of pressure (1 atm) ofless than about 250° C., preferably less than about 235° C., at 1atmosphere (atm) of pressure. Conversely, the term “nonvolatile” as usedherein refers to those materials which do not have a measurable vaporpressure under 1 atmosphere of pressure, at about 50% relative humidity,at about 25° C.

[0093] The term “nonpolar” as used herein refers to those materialswhich have a solubility parameter of less than 8.0 (cal/cm³)^(0.5),preferably from about 5.0 (cal/cm³)^(0.5) to less than 8.0(cal/cm³)^(0.5), more preferably from 6.0 (cal/cm³)^(0.5) to about 7.60(cal/cm³)^(0.5).

[0094] Solubility parameters for the liquid carriers and other materialsdescribed herein are determined by methods well known in the chemicalarts for establishing the relative polar character of a solvent or othermaterial. A description of solubility parameters and means fordetermining them are described by C. D. Vaughan, “Solubility Effects inProduct, Package, Penetration and Preservation” 103 Cosmetics andToiletries 47-69, October 1988; and C. D. Vaughan, “Using SolubilityParameters in Cosmetics Formulation”, 36 J. Soc. Cosmetic Chemists319-333, September/October, 1988, which descriptions are incorporatedherein by reference.

[0095] Nonlimiting examples of suitable silicone-containing liquidcarriers include volatile or nonvolatile silicones, modified ororganofunctional silicones, and combinations thereof. The volatilesilicone carriers may be cyclic, linear or branched chained siliconeshaving the requisite volatility defined herein. The nonvolatilesilicones are preferably linear silicones. The modified ororganofunctional silicone carriers include polyalkylsiloxanes,polyalkyarylsiloxanes, polyestersiloxanes, polyethersiloxane copolymers,polyfluorosiloxanes, polyaminosiloxanes, and combinations thereof.

[0096] The modified silicone carriers are typically liquid under ambientconditions, and have a preferred viscosity of less than about 100,000centistokes, more preferably less than about 500 centistokes, even morepreferably from about I centistoke to about 50 centistokes, and mostpreferably from about I centistoke to about 20 centistokes. Thesemodified silicone carriers are generally known in the chemical arts,some examples of which are described in 1 Cosmetics, Science andTechnology 27-104 (M. Balsam and E. Sagarin ed. 1972); U.S. Pat. No.4,202,879, issued to Shelton on May 13, 1980; U.S. Pat. No. 5,069,897,issued to Orr on Dec. 3, 1991; which descriptions are incorporatedherein by reference.

[0097] Suitable modified silicone carriers include, but are not limitedto, compounds or materials such as those defined hereinabove and whichare generally characterized as follows: silicone polyethers or siliconeglycols (such as dimethicone copolyol); silicone alkyl-linked polyethers(such as Goldschmidt EM-90 or EM-97); siloxane surfactants of apendant/rake/comb configuration, silicone surfactants of a trisiloxaneconfiguration, and silicone surfactants of an ABA/alpha-omega blockcopolymers (such as polyoxyalkylenes, polyoxyethylene or ethoxylated,polyoxyethylene/polyoxypropylene or ethoxylated/propoxylated); aromaticsubstituted silicone emollients (such as phenyl, alpha-methyl styryl,styryl, methylphenyl, alkylphenyl); silicone copolymers with otherfunctional groups include: hydrogen, alkyl, methyl, amino,trifluoropropyl, vinyl, alkoxy, arylalkyl, aryl, phenyl, styryl,polyethers, esters, carboxylics; alkylmethyl siloxanes or silicone waxes(such as hexyl, octyl, lauryl, cetyl, stearyl); nonionic functionalsiloxane copolymers with terminal groups being silanol ortrimethylsiloxy; nonionic functional siloxanes with backbone groupsbeing trisiloxane or methicone linked; nonionic silicone surfactants;tetraethoxysilane; tetramethoxysilane; hexamethoxysilicone;oxmethoxytrisiloxane; silicone emulsifiers; silicone or siloxane resins,alkyl silicone resins, polyoxyalkylene silicone resins; MQ Resins suchas Shiseido/Shin-etsu, e.g. Japanese Patent Publication JP86143760 orfrom Walker Chem. 6MBH (described in EP722970); alkoxysiloxanes;alkoxysilanes; methicones (polymethylalkylsiloxanes); and combinationsthereof.

[0098] Nonlimiting examples of suitable modified silicone carriers foruse in the antiperspirant and deodorant compositions described hereininclude the following modified silicones available from Dow Corning:DC-556 Cosmetic Grade Fluid (phenyl trimethicone); DC-1784 Emulsion;DC-AF Emulsion; DC-1520-US Emulsion; DC-593 Fluid (Dimethicone [and]Trimethylsiloxysilicate); DC-3225C Fluid (Cyclomethicone [and]Dimethicone Copolyol); DC-1401 (Cyclomethicone [and] Dimethiconol);DC-5640 Powder; DC-Q2-5220 (Dimethicone Copolyol); DC Q2-5324(Dimethicone Copolyol); DC-2501 Cosmetic Wax (Dimethicone Copolyol);DC-2502 Fluid (Cetyl Dimethicone); DC-2503 Wax (Stearyl Dimethicone);DC-1731 Volatile Fluid (Caproyl Trimethicone); DC-1-3563 (Dimethiconal);DC-X2-1146A (Cylcomethicone [and] Dimethiconol); DC-7224(Trimethylsilylamodimethicone); DC-X2-1318 Fluid (Cyclomethicone [and]Vinyldimethicone); DC-QF1-3593A fluid (Trimethylsiloxysilicate) andcombinations thereof.

[0099] Other nonlimiting examples of suitable modified silicone carriersinclude the following modified silicones available from GeneralElectric: GE CF-1142 (Methylphenyl Siloxane Fluid); GE SF-1328; GESF-1188 (Dimethicone copolyol); GE SF-1188A, and combinations thereof.

[0100] Other nonlimiting examples of suitable modified silicone carriersinclude the following modified silicones available from Goldschmidt:Abil EM-90 (silicone emulsifier); Abil EM-97 (polyether siloxane);Tegomer H-Si 2111, H-Si 2311, A-Si 2120, A-Si 2320, C-Si 2141, C-Si2341, E-Si 2130, E-Si 2330, V-Si 2150, V-Si 2550, H-Si 6420, H-Si 6440,H-Si 6460 (Alpha-Omega Dimethicone Copolymers) and combinations thereof.

[0101] Other nonlimiting examples of suitable modified silicone carriersinclude the following: Masil 756 from PPG Industries (TetrabutoxypropylTrisiloxane); Silicate Cluster from Olin(Tris[tributoxysiloxy]methylsilane); silicone copolymer F-754(dimethicone copolymer from SWS Silicones); and combinations thereof.

[0102] Non-limiting examples of suitable volatile silicones for use inthe antiperspirant and deodorant compositions herein are described inTodd et al., “Volatile Silicone Fluids for Cosmetics”, Cosmetics andToiletries, 91:27-32 (1976), which descriptions are incorporated hereinby reference. Preferred among these volatile silicones are the cyclicsilicones having from about 3 to about 7, more preferably from about 4to about 5, silicone atoms. Most preferably are those which conform tothe formula:

[0103] wherein n is from about 3 to about 7, preferably from about 4 toabout 5, most preferably 5. These volatile cyclic silicones generallyhave a viscosity value of less than about 10 centistokes. All viscosityvalues described herein are measured or determined under ambientconditions, unless otherwise specified. Suitable volatile silicones foruse herein include, but are not limited to, Cyclomethicone D-5(commercially available from G. E. Silicones); Dow Corning 344, and DowCorning 345 (commercially available from Dow Corning Corp.); GE 7207, GE7158 and Silicone Fluids SF-1202 and SF-1173 (available from GeneralElectric Co.); SWS-03314, SWS-03400, F-222, F-223, F-250, F-251(available from SWS Silicones Corp.); Volatile Silicones 7158, 7207,7349 (available from Union Carbide); Masil SF-V (available from Mazer);and combinations thereof.

[0104] The non-volatile silicone carriers for use in the antiperspirantand deodorant compositions described herein are preferably linearsilicones which include, but are not limited to, those which conform toeither of the formulas:

[0105] wherein n is greater than or equal to 1. These linear siliconematerials will generally have viscosity values of up to about 100,000centistoke, preferably less than about 500 centistoke, more preferablyfrom about 1 centistoke to about 200 centistoke, even more preferablyfrom about 1 centistoke to about 50 centistoke, as measured underambient conditions. Examples of non-volatile, linear silicones suitablefor use herein include, but are not limited to, hexamethyldisiloxane;Rhodorsil Oils 70047 (available from Rhone-Poulenc); Masil SF Fluidavailable from Mazer; Dow Corning 200, Dow Corning 225, Dow Corning1732, Dow Corning 5732, Dow Corning 5750 (available from Dow CorningCorp.); SF-96, SF-1066 and SF18(350) Silicone Fluids (available fromG.E. Silicones); Velvasil and Viscasil (available from General ElectricCo.); Silicone L-45, Silicone L530, Silicone L-531 (available from UnionCarbide); Siloxane F-221 and Silicone Fluid SWS-101 (available from SWSSilicones); and combinations thereof.

[0106] The antiperspirant and deodorant compositions preferably comprisea combination of volatile and nonvolatile silicone materials, morepreferably a combination of volatile and nonvolatile silicone carrierliquids. Nonlimiting examples of suitable combinations of such siliconematerials are described in U.S. Pat. No. 5,156,834 (Beckmeyer et al.),which description is incorporated herein by reference.

[0107] Nonlimiting examples of suitable polar organic liquid carriersfor use in the antiperspirant and deodorant compositions describedherein include mono and polyhydric alcohols, fatty acids, esters of monoand dibasic carboxylic acids with mono and polyhydric alcohols,polyoxyethylenes, polyoxypropylenes, polyalkoxylates ethers of alcohols,and combinations thereof. Preferably such liquid carriers are alsowater-immiscible liquids under ambient conditions. Other suitablewater-immiscible, polar organic liquid carriers or solvents for useherein are described in Cosmetics, Science, and Technology, Vol. 1,27-104, edited by Balsam and Sagarin (1972); U.S. Pat. No. 4,202,879issued to Shelton on May 13, 1980; and U.S. Pat. No. 4,816,261 issued toLuebbe et al. on Mar. 28, 1989, which descriptions are incorporatedherein by reference.

[0108] Other suitable liquid carriers for use in the antiperspirant anddeodorant compositions described herein include anhydrous,water-miscible, polar organic liquid carriers or solvents, examples ofwhich include short chain alcohols such as ethanol, and glycol solventssuch as propylene glycol, hexylene glycol, dipropylene glycol,tripropylene glycol, and so forth. Other suitable similar solvents alsoinclude polyalkoxylated carriers such as polyethylene glycols,polyproylene glycols, combinations and derivatives thereof, and soforth. Non-limiting examples of polar solvents suitable for use hereinare described in U.S. Pat. No. 5,429,816, which description isincorporated herein by refererence. Other suitable polar solventsinclude phthalate co-solvents, benzoate co-solvents, cinnamate esters,secondary alcohols, benzyl acetate, phenyl alkane, and combinationsthereof.

[0109] Nonlimiting examples of suitable nonpolar liquid carriers for usein the antiperspirant and deodorant compositions described hereininclude mineral oil, petrolatum, isohexadecane, isododecane, varioushydrocarbon oils such as the Isopar or Norpar series available fromExxon Corp., the Permethyl series available from Persperse, and theSoltrol series available from Phillips Chemical, and any other polar ornonpolar, water-miscible, organic carrier liquid or solvent known orotherwise safe and effective for topical application to human skin.

[0110] Other suitable liquid carriers for use in the antiperspirant anddeodorant compositions described herein include fluorine-containingliquid carriers such as fluorochemicals including fluorosurfactants,fluorotelemers, and perfluoropolyethers, some examples of which aredescribed in Cosmetics & Toiletries, Using Fluorinated Compounds inTopical Preparations, Vol. 111, pages 47-62, (October 1996), whichdescription is incorporated herein by reference. More specific examplesof such liquid carriers include, but are not limited to,perfluoropolymethyl isopropyl ethers, perfluoropolypropylethers,acrylamide fluorinated telomer, fluorinated amide surfactants,perfluorinated thiol surfactants. Other more specific examples include,but are not limited to, the polyperfluoroisopropyl ethers available fromDupont Performance Chemicals under the trade name Fluortress® PFPE oils,and the series of fluorosurfactants available from Dupont PerformanceChemicals under the trade name Zonyl® Fluorosurfactants.

[0111] The antiperspirant compositions described herein may furthercomprise dimethiconol as an optional liquid carrier. Preferredconcentrations of the dimethiconol range from about 0.1% to about 50%,more preferably from about 1% to about 35%, even more preferably fromabout 2% to about 20%, by weight of the selected antiperspirantcomposition. Dimethiconols suitable for use as an optional liquidcarrier include those corresponding to the formula:

[0112] wherein n is number having a value of zero or greater, preferablyfrom about 1 to about 100, more preferably from about 1 to about 50,even more preferably from about 1 to about 10. Nonlimiting examples ofsuitable dimethiconols include Masil® SFR 70, Mazol® SFR 18,000, Mazol®SFR 50,000, Mazol® SFR 100, Mazol® SFR 150,000, Mazol® SFR 750, Mazol®SFR 2000, and Mazol® SFR 3500, all available from PPG/SpecialtyChemicals; Unisil SF-R available from Universal Preservative; andcombinations thereof. Other available dimethiconols include Abil® OSW12, OSW13, Abil® OSW 15, and Abil® CK, all available from Goldschmidt;Dow Corning® 1401 Fluid, Dow Corning® Q2-1403 Fluid, Dow Corning®X2-1286 Fluid, all available from Dow Corning; Tri-Sil HGC 5000available from Tri-K Industries; and combinations thereof.

[0113] Optional Components

[0114] The antiperspirant and deodorant compositions for use in theapplicator of the present invention may further comprise one or moreoptional components which may modify the physical or chemicalcharacteristics of the compositions or serve as additional “active”components when deposited on the skin. The compositions may also furthercomprise optional inert ingredients. Many such optional materials areknown for use in antiperspirants, deodorants or other personal carecompositions, and may be used in the antiperspirant and deodorantcompositions described herein, provided that such optional materials arecompatible with the essential materials described herein, or do nototherwise unduly impair product performance.

[0115] Nonlimiting examples of optional ingredients suitable for use inthe antiperspirant and deodorant compositions described herein includepH buffering agents; additional emollients; humectants; dyes andpigments; medicaments; emulsifiers; chelants; distributing agents;preservatives; residue masking agents; wash-off aids; and soothingagents such as aloe vera, allantoin, D-panthenol, avocado oil and othervegetable oils, and lichen extract.

[0116] Rheology

[0117] One embodiment of the antiperspirant compositions describedherein are antiperspirant creams which have a select rheology profile.The rheology profile as defined herein is a combination of selectproduct delta stress (dyne/cm²) and static yield stress (dyne/cm²)values for the antiperspirant cream compositions. Methods for measuringor determining each of these essential characteristics of the rheologyprofile are described in detail hereinafter. Rheology methodologies arecarried out at 27° C., 15% relative humidity, unless otherwisespecified.

[0118] 1. Methodology: Delta Stress and Static Yield Stress

[0119] To determine delta stress and static stress yield values for theantiperspirant cream compositions, the compositions are analyzed using aRheometrics Dynamic Stress Rheometer (available from Rheometrics Inc.,Piscatawany, N.J., U.S.A) with data collection and analysis performedusing Rhios software 4.2.2 (also available from Rheometrics Inc.,Piscatawany, N.J., U.S.A.). The rheometer is configured in a parallelplate design using a 25 mm upper plate (available as part numberLS-PELT-IP25 from Rheometrics Inc., Piscatawany, N.J., U.S.A.).Temperature control is set at 37° C. Analysis of the antiperspirantcream is performed in the “Stress Sweep: steady sweep” default testmode. Rheometer settings are initial stress (1.0 dyne/cm²), final stress(63,930 dyne/cm²), stress increment (100 dyne/cm²), and maximum time perdata point (5 seconds).

[0120] The term “static yield stress” as used herein refers to theminimum amount of stress (dyne/cm²) that must be applied to theantiperspirant cream composition to move the upper plate of theRheometrics Dynamic Stress Rheometer a distance of about 4.2 microradians, in accordance with the analysis methods described herein. Inother words, static yield stress represents the point in a stress sweepanalysis (described herein) of a product at which point the rheometer isfirst capable of measuring product viscosity.

[0121] The term “delta stress” as used herein is determined bysubtracting the static yield stress from the dynamic yield stress of acomposition. The dynamic yield stress is the point at which the measuredviscosity begins to rapidly decline. This can be easily determined byfinding the last stress value where the increment between stress valuesis 100 dynes/cm². In other words, the delta stress of the compositionrepresents the incremental amount of stress that must be applied to thecomposition, beyond the static yield stress of the composition, tosubstantially liquefy the composition.

[0122] The antiperspirant cream composition is evaluated for rheologycharacteristics after the composition has been packaged in theapplicator device of the present invention. A section of the compositionis carefully removed from the applicator so that the product issubjected to minimal shear, and especially so that it is not permittedto curl or otherwise reconfigure to a shape other than that of thesection as it was removed from the composition. The section is carefullyplaced flat on the lower plate of the rheometer taking care to minimizethe application of shear stress on the section during the placement. Thearea of the placed section is at least about the size of the upper plateto assure proper contact between the two plates during testing. Theupper plate is then lowered toward the bottom plate, and positionedabout 2 mm above the lower plate, and therefore about 1 mm from theproduct section which is positioned flat on the lower plate. The upperplate is further lowered at a minimal rate toward the lower plate, andpositioned about 1.000 (±0.002) mm above the lower plate, at which pointthe product is gently positioned between and contacting each of thelower and upper plates. Excess product extending away from and aroundthe parallel positioned plates is gently removed using a spatula, andtaking care to subject the product positioned between plates to minimalor no further shear from the spatula. The solvent guard pad on therheometer is saturated with the type of liquid carrier corresponding tothat in the test product. The solvent guard is lowered over the parallelplates to prevent solvent loss from the test product that is positionedbetween the plates during analysis. The product is now ready forrheology analysis and determination of dynamic stress, static yieldstress, and delta stress.

[0123] Product samples are subjected to rheological test and evaluationin accordance with the above described methodology. Data from the abovedescribed analysis can be plotted as viscosity (pascal·sec.) on a logscale versus linear applied stress (dyne/cm²). The initial point atwhich the instrument measures a viscosity is the static yield stress(i.e. the lowest stress at which the instrument shows a non-zeroviscosity). The dynamic yield stress is the point at which the measuredviscosity begins to rapidly decline. This can be easily determined byfinding the last stress value where the increment between stress valuesis 100 dyne/cm². The delta stress is then determined by subtracting thestatic yield stress from the dynamic yield stress.

[0124] The antiperspirant cream compositions have a static yield stressvalue of at least about 4,000 dyne/cm², more preferably at least about8,000 dyne/cm², even more preferably at least about 40,000 dyne/cm². Themaximum static yield stress values for the compositions are preferablyless than about 120,000 dyne/cm², more preferably less than about 63,000dyne/cm².

[0125] The delta stress value of the antiperspirant cream compositionsis from about 300 dyne/cm² to about 8,000 dyne/cm², preferably fromabout 1,000 dyne/cm² to about 6,000 dyne/cm², more preferably from about1,000 dyne/cm² to about 5,000 dyne/cm². A delta stress below the minimumlevel can result in solvent syneresis during shear force delivery means,whereas a value above the recited maximum can result in nonuniformspreading of the product onto the skin, and reduced spreadability on theskin, especially on hairy areas of the skin. The delta stress values,therefore, recited herein provide for a smooth creamy product that showsminimal or no solvent syneresis, spreads uniformly over the skin, andspreads especially well over and through hairy areas of the skin.

Skin Care Compositions

[0126] Another suitable category of substances believed suitable for usewith the applicators of the present invention is the class ofcompositions generally referred to as skin care compositions. Suchcompositions include those intended to treat or modify human skin interms of structure, condition, or appearance. By way of example only,and not to be interpreted as limiting, an area of current interest inthe skin care area relates to compositions designed to address issuesassociated with the onset of skin wrinkles. Representative compositionsin this area include salicylic acid technologies, such as thosedisclosed in commonly-assigned, published PCT applications WO 92/09737and WO 92/09739, both published Jun. 10, 1993, and WO 92/08741,published Apr. 29, 1993. Another area of current interest is skin carecompositions containing niacinamide, such as those disclosed inpublished PCT applications WO 96/17672, published May 15, 1997, and WO97/06680, published Oct. 30, 1997. All of these publications are herebyincorporated herein by reference. Other suitable compositions includethose disclosed in commonly-assigned U.S. Pat. Nos. 5,720,961,5,707,635, 5,703,026, 5,700,451, 5,683,706, 5,674,509, and 5,665,364,the disclosures of which are hereby incorporated herein by reference.

Hair Care Compositions

[0127] The applicator of the present invention can also be used fortopical application of hair care products to the hair. Hair careproducts which may be applied include shampoos, rinse-off conditioners,leave-on conditioning products, colorants, hair styling sprays, gels,and mousses.

[0128] Shampoos, used for cleansing hair, generally comprise one or moresurfactants, thickeners or suspending agents, perfumes, and otionallyconditioning or styling agents. Typical shampoos are disclosed in U.S.Reissue Pat. No. 34,584, Grote et al., issued Apr. 12, 1994; U.S. Pat.No. 5,756,436, Royce et al., May 26, 1998; U.S. Pat. No. 5,648,323,Coffindaffer et al., issued Jul. 15, 1997; U.S. Pat. No. 5,612,301,Inman, issued Mar. 18, 1997; U.S. Pat. No. 5,573,709, Wells, issued Nov.12, 1996; U.S. Pat. No. 5,151,210, Steuri et al., issued Sep. 29, 1992;U.S. Pat. No. 4,704,272, Oh, issued Nov. 3, 1987; U.S. Pat. No.4,705,681, Maes et al., issued Nov. 10, 1987; U.S. Pat. No. 4,387,090,Bolich Jr. Et al., issued Jun. 7, 1983; U.S. Pat. No. 4,379,753, BolichJr., issued Apr. 12, 1983; and U.S. Pat. No. 4,345,080, Bolich Jr. etal., issued Aug. 17, 1982.

[0129] Hair conditioning products are generally used to applyconditioning agents to the hair after shampooing to improve detanglingand/or provide soft hair feel. Typical rinse-off conditioners aredisclosed in U.S. Pat. No. 5,667,771, Carballada et al., issued Sep. 16,1997; U.S. Pat. No. 5,482,703, Pings, issued Jan. 9, 1996; U.S. Pat. No.5,106,609, Bolich Jr. et al., issued Apr. 21, 1992; U.S. Pat. No.5,104,646, Bolich Jr. et al., issued Apr. 14, 1992; and U.S. Pat. No.4,387,090, Bolich Jr. issued Jun. 7, 1983. Typical leave-on conditioningproducts are disclosed in U.S. Pat. No. 5,674,478, Dodd et al, Oct. 7,1997.

[0130] Hair styling products, such as aerosol and non-aerosol hairsprays, mousses, and gels are disclosed in U.S. Pat. No. 5,750,122,Evans et al., May 12, 1998; U.S. Pat. No. 5,730,966, Torgerson et al.,Mar. 24, 1998; U.S. Pat. No. 5,674,478, Dodd et al, Oct. 7, 1997; U.S.Pat. No. 5,658,557, Bolich Jr. et al., issued Aug. 19, 1997; U.S. Pat.No. 5,166,276, Hayama et al., issued Nov. 24, 1992; and U.S. Pat. No.5,753,216, Leitch et al., issued May 19, 1998.

[0131] Hair coloring products have been generally disclosed in U.S. Pat.No. 5,679,114, Haning et al., issued Oct. 21, 1997; U.S. Pat. No.5,597,386, Igarashi et al., issued Jan. 28, 1997; U.S. Pat. No.5,435,810, Prota et al, issued Jul. 25, 1995; U.S. Pat. No. 5,356,439,Schultz et al., issued Oct. 18, 1994; U.S. Pat. No. 4,183,366, Bartuskaet al., issued Jan. 15, 1980; and U.S. Pat. No. 4,200,432, Kalopissis etal., issued Apr. 29, 1980.

Other Substances

[0132] While much of the foregoing discussion has focused uponparticular substances such as antiperspirant compositions which haveproven suitable for use with applicators according to the presentinvention, it should be understood that the principles of the presentinvention are believed to apply to other applicator/substancecombinations wherein the applicator is designed to account for theparticular characteristics of the substance and the nature of theapplication environment. For example, it is believed that othercompositions such as sunscreens, cooking products such as fats, oils,and shortenings, waxes such as shoe polishes and the like, and othersubstances may be suitable for use with applicators as described herein.

[0133] In accordance with the present invention, the substance utilizedin combination with the deformable material exhibits a selection ofphysical properties which enable it to be dispensed from its protectedorientation within the three-dimensional structure and applied to thetarget surface. Such dispensation may be partial, or substantially ortotally complete in nature.

[0134] To facilitate such dispensing, substance properties which arebelieved to be important include the relative affinity of the substancefor the target surface versus that for the deformable material and theapparent viscosity or flowability of the substance after activation ofthe three-dimensional structure. It is presently believed that thesubstance should preferentially adhere to the target surface to agreater extent than to the deformable material and/or to a greaterextent than for other portions of the substance itself. Saiddifferently, the substance has a greater affinity for the target surfacethan for itself and/or for the deformable sheet material.

[0135] Substances may inherently possess viscosity and flowcharacteristics which permit their liberation from their protectedlocation within the sheet material or may require viscosity modificationto permit liberation and dispersal. Viscosity modification may beobtained by the selection of substances which undergo a change inviscosity in response to the mode of activation selected. For example,for a mechanical activation such as a compressive force it may bedesirable, and preferably, to employ substances which are commonlyreferred to as “shear-thinning” (pseudoplastic) substances. Examples ofsuch substances include polymer solutions, many gels and pastes such asdentrifice and body creams, paints, gelled wood stains, etc. Othermaterials behave as shear-thinning materials only after a certainthreshold shear (yield stress) is reached or exceeded. Such materialsare commonly referred to as Bingham plastic materials, and one commonexample of a substance exhibiting such behavior is the type of condimentknown as ketchup.

[0136] Some of the factors believed to influence the adhesion oraffinity of the substance for the target surface include: electrostaticor electrical charges; chemical bonds via hydrogen bonding, covalentbonding, ionic bonding, partial ionic bonds (partial dipolarattraction), van der Walls forces, osmotic forces, etc.; capillarypressure (suction); adsorption; absorption; vacuum/suction; etc. Otherimportant factors include the wettability of the substance upon thetarget surface, as reflected by the contact angle of the substance onthe target surface.

[0137] To facilitate spreading or dispersal of the substance upon thetarget surface, particularly to counteract the tendency of the substanceto remain in a localized distribution pattern given the localizedorientation upon the deformable substance, it is presently preferred toutilize substances which are tailored so as to be wettable on the targetsurface. Other factors which may aid in dispersion or distribution ofthe substance upon the target surface include the use of substanceswhich exhibit a shear-thinning behavior, as well as mechanical spreadingaction provided by the user of the composite sheet material to impart alateral mechanical motion after activation but prior to removal of thedeformable material from the target surface. Such lateral mechanicalaction may also provide additional interaction with the substance suchas for shear-thinning substances and may provide additional benefitssuch as lathering, foam generation, scrubbing/abrasive action, etc.

[0138] Successful dispersal occurs when a portion of the deposited ordispensed substance subsequently coats a portion of the target surfacewhere the substance was not originally deposited. Upon removal of thesheet material from the target surface, at least some of the substanceremains located on the target surface, preferably in asubstantially-uniform fashion.

[0139] As discussed above, a wide variety of substances may be selectedfor use in accordance with the principles of the present invention.Representative substances for illustrative purposes include cleansingagents such as soaps and detergents, emollients such as lotions,medicinal agents such as ointments, anti-inflammatory creams, etc.,health and beauty care products, including antiperspirants, deodorants,cosmetics, fragrances, and the like. Other more diverse applications forsuch a sheet material include applicators for automotive and householdproducts such as lubricants, colorants, protectants such as oils andwaxes, adhesives, preservatives, and the like, as well as food-orientedapplications such as condiments (mustard, ketchup, etc.).

[0140] Multiple substances may also be employed which are not onlyprotected from inadvertent contact but segregated from one anotherinitially (on the same face of, or on opposing faces of, the sheetmaterial) and be commingled during the activation process or duringsubsequent dispensing and/or dispersion operations. Such an arrangementmay be particularly useful for substances which beneficially interactwith one another (e.g., co-dispensing epoxies, catalyzed reactions,etc.) to provide additional functionality with each other and/or withthe target surface. It may also be desirable to provide for progressiveor sequential substance delivery by tailoring the geometry of theapplicator or substance properties to provide for initial applicationfollowed by additional progressive dispensing with the passage of time,increased pressure, etc.

[0141] 3. Methods of Manufacture.

[0142] The applicators of the present invention may be manufactured inany manner suitable for the intended geometry and intended materials andsubstances involved. By way of example, for the presently preferred foammaterials articulated above, the configuration of FIG. 1 may bemanufactured by forming the plurality of apertures and reservoirs viathermal embossing with a heated die to the desired depth, then eitherinjecting the substance into the reservoirs or flooding the substanceinto/onto the applicator and doctoring off the excess substance. A labelor seal is then applied over the delivery zone and secured by thermal oradhesive means. The applicator may then be die cut to the final shape,or alternatively the die cutting step may be accomplished at the sametime as the formation of the reservoirs, or any other suitablearrangement of steps. The substance may be heated or otherwise madeflowable for such a process if necessary.

[0143] For an embodiment with a single reservoir such as that of FIG. 4,the application surface may be similarly manufactured, the backsheet maybe peripherally joined by thermal or other means, and the substance maybe injected into the reservoir from a single source or multiple sourcesif desired.

[0144] While particular embodiments of the present invention have beenillustrated and described, it will be obvious to those skilled in theart that various changes and modifications may be made without departingfrom the spirit and scope of the invention, and it is intended to coverin the appended claims all such modifications that are within the scopeof the invention.

What is claimed is:
 1. An applicator for applying and distributing asubstance onto a target surface, said applicator comprising: (a) asubstantially planar sheet of compressible, conformable material havingopposed first and second surfaces and an interior region between saidfirst and second surfaces, said sheet of material having a thicknessbetween said first and second surfaces which decreases when said sheetof material is subjected to an externally-applied force in a directionsubstantially normal to said first surface; (b) at least one discretereservoir extending inwardly of said first surface into the interior ofsaid sheet of material; (c) a substance at least partially filling saidreservoir; and (d) at least one discrete aperture formed in said firstsurface, said aperture being in fluid communication with said reservoir;whereby compression of said sheet of material via an externally-appliedforce substantially normal to said first surface expresses said productfrom said aperture and translational motion of said first surfacerelative to a target surface applies and distributes said product ontosaid target surface.
 2. The applicator of claim 1 , wherein saidapplicator includes a plurality of apertures forming a delivery zoneadjacent to one end of said applicator.
 3. The applicator of claim 1 ,wherein said substance fills said reservoir to a level at least equal tosaid first surface.
 4. The applicator of claim 1 , wherein saidreservoir defines an interior volume which decreases when said thicknessis reduced by an externally-applied force.
 5. The applicator of claim 1, wherein said applicator includes a plurality of apertures.
 6. Theapplicator of claim 1 , wherein said applicator includes a plurality ofreservoirs.
 7. The applicator of claim 1 , wherein said applicatorincludes a plurality of apertures and a corresponding plurality ofreservoirs, each of said apertures being in fluid communication with oneof said reservoirs.
 8. The applicator of claim 1 , wherein said aperturefully penetrates said first and second surfaces and said reservoir isformed between said second surface and a backing sheet peripherallyjoined thereto.
 9. The applicator of claim 1 , wherein said reservoirextends inwardly of said first surface into the interior of said sheetof material but does not penetrate said second surface.
 10. Theapplicator of claim 1 , wherein said reservoir extends inwardly of saidfirst surface into the interior of said sheet of material a distancewhich is less than said thickness.
 11. The applicator of claim 1 ,wherein said sheet material is resilient in compression.
 12. Theapplicator of claim 1 , wherein said sheet material is resilient inbending.
 13. The applicator of claim 1 , wherein said sheet materialcomprises a closed-cell foam material.
 14. The applicator of claim 1 ,wherein said applicator includes a removable cover sheet for enclosingsaid aperture prior to use.
 15. The applicator of claim 1 , wherein saidapplicator includes a plurality of reservoirs and a correspondingplurality of apertures, and wherein said reservoirs include multiplediverse substances.
 16. An applicator for applying and distributing asubstance onto a target surface, said applicator comprising: (a) asubstantially planar sheet of compressible, conformable material havingopposed first and second surfaces and an interior region between saidfirst and second surfaces; (b) at least one discrete aperture extendinginwardly of said first surface into the interior of said sheet ofmaterial a distance which is less than the distance between said opposedfirst and second surfaces to form a corresponding product reservoir. 17.The applicator of claim 16 , wherein said compressible, conformablematerial comprises a closed-cell foam material.
 18. A method of makingan applicator for applying and distributing a substance onto a targetsurface, said method comprising the steps of: (a) providing asubstantially planar sheet of compressible, conformable material havingopposed first and second surfaces and an interior region between saidfirst and second surfaces, said sheet of material having a thicknessbetween said first and second surfaces which decreases when said sheetof material is subjected to an externally-applied force in a directionsubstantially normal to said first surface; (b) forming at least onediscrete reservoir extending inwardly of said first surface into theinterior of said sheet of material; (c) at least partially filling saidreservoir with a substance; and (d) forming at least one discreteaperture in said first surface, said aperture being in fluidcommunication with said reservoir.
 19. The method of claim 18 , whereinsaid reservoir is formed by thermal embossing.
 20. The method of claim18 , wherein said substance is injected into said reservoir.
 21. Theapplicator of claim 1 , wherein said reservoir is a slot type reservoir.22. The applicator of claim 1 , wherein said reservoir is anaperture-channel type reservoir.
 23. The applicator of claim 1 , whereinsaid reservoir is an aperture-channel type reservoir positioneddiagonally at a 45° angle.
 24. The applicator of claim 1 , wherein saidreservoir has an aspect ratio of about 5 or below.